Motorized swivel recliner

ABSTRACT

A reclining chair system that features a recliner motion mechanism used for positioning a reclining unit that includes a seat and a seat back having a fixed positional relationship to each other, including a gear rack adapted to receive a gear that travels in engagement with the gear rack, a gear shaft attached to the gear and driven by a drive motor for rotating the gear and causing it to move along the gear rack, a connection between the drive motor and seat that causes the seat back to move, as the gear travels along the gear rack, at least at the seat back&#39;s lower edge, and generally in the direction of the gear rack, and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the seat back at a position for causing a rotational movement of the seat back relative to a rotational axis of the gear, to guide the seat back during movement of the gear along the gear rack.

FIELD OF THE INVENTION

The present invention relates to furniture. More particularly, this invention relates to furniture and apparatus, and methods for making the same, for positioning individuals in relaxing, comfortable, and/or healthful positions.

BACKGROUND OF THE INVENTION

The term zero gravity positioning relates to the orientation of the legs above the level of the heart. It is also called the “90-90” position and the Trendleberg position. The latter term is commonly used in hospitals when a bed is positioned with the legs elevated in order to reduce tension and improve blood circulation. The term “zero gravity,” or “Z.G.,” stems from suggestions that the human body naturally assumes a similar orientation with respect to the legs when relaxed and suspended in weightlessness.

Chairs have existed since prehistoric times, and recliners have been manufactured for centuries. More recently, relatively speaking, chairs that pivot and chairbacks that fold have been developed. Another improvement consists of some form of leg support while a chair is in a reclined position.

SUMMARY OF THE INVENTION

A family of reclining chair systems has been developed that features, in one aspect, a recliner motion mechanism used for positioning a recliner that includes a seat and a seat back having a fixed positional relationship to each other. According to various embodiments of the present invention, the recliner motion mechanism includes the following: a gear rack adapted to receive a gear that travels in engagement with the gear rack, a gear shaft attached to the gear and driven by a drive motor for rotating the gear and causing it to move along the gear rack, a connection between the drive motor and seat that causes the seat back to move, as the gear travels along the gear rack, at least at the seat back's lower edge, and generally in the direction of the gear rack, and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the seat back at a position for causing a rotational movement of the seat back relative to a rotational axis of the gear, to guide the seat back during movement of the gear along the gear rack.

According to various embodiments, the invention also includes a gear rack and the curved track adapted to move the seat and seat back into a zero gravity position, wherein the gear is positioned by the motor at a greater distance from a recliner base when the seat back is in a generally reclined position than when the seat back is in a generally upright position, and wherein the motor is powered by a battery. It will be understood by persons versed in the field that the motor may alternatively be powered, for example, using a power cord that plugs into a power outlet. Moreover, in embodiments using a power cord, for example, various precautions may be taken to prevent the undesirable winding of the cord around the chair.

Other embodiments include one or more of the following features. A base unit that supports a seat, wherein the base unit does not recline, the seat has a center of gravity, and the seat is operatively connected to a back support member and a leg support member, wherein the seat, back support member, and leg support member have a fixed relative position orientation to each other and can be reclined as a reclining unit from a generally upright sitting position to a reclined position, a motive drive including a motor that operates to move the center of gravity of the seat forward when shifting the unit to the reclined position, and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the back support member to guide the back support member down during forward movement of the center of gravity of the seat, wherein the motive drive and the curved track are adapted such that the reclined position is a zero gravity position and wherein the motor is positioned at a higher altitude level when the reclining unit is in the reclined position than when the unit is in the generally upright sitting position. A swivel mechanism is provided to permit the base unit to pivot at least partially, and preferably 360°, around a vertical axis. A battery is preferably provided to power the motive drive.

In still other embodiments, a reclining chair further includes a base unit that supports a seat, and the seat is operatively connected to a back support member and a leg support member, wherein the seat, back support member, and leg support member have a fixed relative position orientation to each other and can be reclined as a reclining unit from a generally upright sitting position to a reclined position, a motive drive element that operates to move the reclining unit from the generally upright sitting position to the reclined position, and a fixed track guide element, the motive drive element and the fixed track guide element adapted to permit a rotation of the reclining unit with a simultaneous forward translation of the reclining unit when the reclining unit is moving from the generally upright sitting position to the reclined position, wherein the base unit is adapted to permit the unit to pivot at least partially around a vertical axis.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from accompanying drawings, in which like reference characters refer to like parts throughout, and from the following detailed description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a recliner according to an embodiment of the present invention.

FIG. 2 is a partial side view of a recliner in an upright position according to an embodiment of the present invention.

FIG. 3 is a partial side view of the recliner shown in FIG. 2 in a partially reclined position according to an embodiment of the present invention.

FIG. 4 is a partial side view of the recliner shown in FIGS. 2 and 3 in a zero gravity position according to an embodiment of the present invention.

FIG. 5 is a partial side view of armrest and motion bracket assemblies according to an embodiment of the present invention.

FIG. 6 is a partial front view of motion bracket, armrest, and motor assemblies according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an example of an architecture in accordance with an aspect of the invention is depicted generally at 100. The system architecture includes a seat, seat back, and footrest member 110, wherein the seat, seat back and armrest have a fixed positional relationship to one another. Member 110 can be positioned in an upright position and reclined to a zero gravity position. Member 110 is supported by armrests 120 and by a base 130. In this example, the armrests 120 do not move as member 110 is reclined. Member 110 and the armrests 120 can pivot side-to-side on base 130 about a vertical axis. Member 110 and armrests 120 are upholstered in the view displayed in FIG. 1.

Referring to FIG. 2, a side view of an embodiment of the invention in an upright position is shown. The upholstery is omitted in the drawing. A backrest frame 205 is constructed using a preferably rigid material (e.g., tubular steel) with an “S” shape to provide a user back support while upright and in the reclined Z.G. position. Backrest frame 205 is connected to a motion bracket 206, which in turn connects to a seat and footrest frame 207. In various embodiments, motion bracket 206 is also constructed using a rigid material such as steel.

According to various embodiments of the invention, the connection of backrest frame 205 to motion bracket 206, and the connection of motion bracket 206 to footrest frame 207, may be permanent and/or made before the recliner chair is purchased by a user. According to other embodiments, these components may be detachably connected to one another prior to purchase. In yet other embodiments, these components may be either detachably or permanently connected by a user following the purchase of the chair (e.g., in the convenience of the user's home). In this last case, as will be appreciated by those versed in the field, transport of the partially unassembled recliner chair will generally be easier than if the chair was constructed prior to transport (e.g., by a merchandiser or manufacturer prior to the purchase of the recliner chair). Additionally, in this case, separate upholstery can be added by, e.g., the manufacturer or the user, for many or all of the various parts of the recliner chair (e.g., the backrest frame 205, the seat of the recliner chair, the footrest frame 207, the armrest 220, etc).

Moreover, according to the invention, footrest frame 207 is designed for easy access to and from the chair. Mounted to motion bracket 206 is a motor 211. Motor 211 drives a shaft attached to a gear 213, which moves along a straight rack 215 within the armrest 220. According to various embodiments of the invention, straight rack 215 is made of a rigid material, such as steel. In the embodiment of the invention illustrated in FIG. 2, straight rack 215 is positioned at a 33° incline, which is important but not unique in achieving Z.G. positioning. It will be understood by persons versed in the field that other angles of incline can be used without departing from the principles of the present invention.

When gear 213 is positioned at the bottom of straight rack 215 as illustrated in FIG. 2, backrest frame 205 and footrest frame 207 are oriented in the upright sitting position. By moving gear 213 along straight rack 215 to a position 221, backrest frame 205 and footrest frame 207 are reclined to a Z.G. position (vide FIG. 4). Motion bracket 206 also has mounted a wheel or follower 223, which engages a curved track 225 that forms part of armrest 220. Follower 223 guides and supports backrest frame 205 and footrest frame 207 as motor 211 positions them in sitting or reclined positions.

As the seat moves down curved track 225, and up rack 215, the backrest is reclined following the arch of curved track 225. The end points of curved track 225 and straight rack 215 are important as they define the two key positions of the zero gravity recliner. The particular shape of curved track 225 dictates the amount and speed of travel from a fully upright to a fully reclined position. Armrest 220 also includes a “V” shaped section 227 of the carriage, and a tubular cross member 228 of the carriage. Member 228 connects with a swivel point 229, about which the seat can pivot up to 360° (or more) on base 230. In this example, base 230 is a domed circular disk formed of cast aluminum or other suitable material. The pivoting action at base 230 is achieved by a swivel mechanism 235. A side panel 240 (constructed from, e.g., wood) hides the working parts of armrest 220 and bolts on to V section 227 of the carriage at, in this illustrative embodiment, three attachment points. The remaining four attachment points, one of which is indicated as attachment point 242 in FIG. 2, is used, for example, to hold center section 551 shown in FIG. 5 in place.

Referring to FIG. 3, a side view of the embodiment of the invention illustrated in FIG. 2 is shown in a partially reclined position. Straight rack 215, armrest 220, curved track 225, V section 227 of the carriage, member 228 of the carriage, swivel point 229, base 230, swivel mechanism 235, wooden side 240, and attachment point 242 have not changed positions in FIG. 3 compared to their respective positions shown in FIG. 2. However, motor 211 has positioned gear 213 further up straight rack 215, resulting in a forward translation and a rotation of motion bracket 206 as the wheel or follower 223 moves down along curved track 225; here, follower 223 is illustrated at the mid-point of curved track 225. In this position, the backrest frame 205 is partially reclined, and seat and footrest frame 207 has, relative to the upright position, rotated the user's thighs upward and lifted his legs off the floor.

Referring to FIG. 4, a side view of the embodiment of the invention illustrated in FIGS. 2 and 3 is shown in the zero gravity position. Straight rack 215, armrest 220, curved track 225, V section 227 of the carriage, member 228 of the carriage, swivel point 229, base 230, swivel mechanism 235, wooden side 240, and attachment point 242 have not changed positions in FIG. 4 compared to their respective positions shown in FIGS. 2 and 3. However, motor 211 has positioned gear 213 to the top of straight rack 215 and follower 223 has moved to the bottom of curved track 225. Motion bracket 206 has moved to its forwardmost position (i.e., to the furthest point left looking from the side in FIG. 4). Backrest frame 205 is reclined, and the footrest and seat frame 207 is positioned to place the user's legs almost horizontally and above the level of the user's heart.

The recliner described herein can be placed in many (e.g., in essence, an infinite number of) positions between the upright and reclined positions shown in FIGS. 2 and 4, respectively. The follower 223 in the curved track 225 defines the motion of the chair, the starting and ending points, and the rate of recline; too slow can be frustrating for the user and too fast can cause physical issues for some people.

The upright position shown in FIG. 2 allows the Z.G. recliner to be more than just a recliner, but also an upright chair suitable for reading or conversing comfortably. This functionality requires good support and seating angles when upright, which necessitates mechanical strength, balanced motion, and added physical space greater than in traditional Z.G. recliners.

The starting point for this chair, in the illustrated embodiment shown in FIG. 2, with the follower 223 at the top of the curved track 225, is with a slightly forward pitched seat. This seat angle makes entrance and exits from the chair easy; it is possible to slide in and out. This is particularly beneficial for users (e.g., those with back pain) that have trouble positioning themselves into, and getting out of, traditional recliner chairs. To further aid with this movement, the arms are far forward, and an indent in the sides allows for an easy grip. Additionally, in various embodiments of the invention, base 230 and/or other components described herein are constructed such that the seat is situated at an elevated level compared to conventional recliner chairs. This also facilitates use of the chair by users. The follower 223 then moves along the curved track 225, which is pitched downward at a steep angle. This is to move the backrest quickly into recline and settle the user into the backrest. As the backrest approaches the mid-reclined position, the curve angles forward so the seat rises quickly and the footrest moves up. The final positioning moves the footrest above the level of the heart, though the back does not recline further.

The straight rack 215 and direct drive in this new design provides the mechanical power for this chair within a small amount of space. The angle of the straight rack 215 speeds the lifting of the seat and the user's legs, reduces slightly the space requirements, and reduces stress on the motor 211 when returning from the Z.G. reclined position.

Referring to FIG. 5, a side view illustration of the armrest and motion bracket assemblies in one embodiment of the invention is shown. Ergonomic considerations include a curved armrest pad 555, designed for use in both the upright and reclined positions, and the forward design of a front grip 557, which permits ease of access to the seat. A center section 551 is designed for ease of assembly of the mechanical components, including assembly of motion bracket 506 (constructed from, e.g., steel), gear 513, and tubular member 528 of the carriage. Member 528 includes swivel point 529, and a battery used to power the drive motor is located in a battery housing 550. Alternatively, an electrical connection to an alternate source of power can be provided. A side panel 540 (constructed from, e.g., wood) is also included, which as described above in connection with panel 240 of FIG. 2, hides various working parts. In FIG. 5, the components are shown for the upright position, with follower 523 at the top of curved track 525 and gear 513 at the lowest position on straight rack 515.

Referring to FIG. 6, a front view illustration of the assemblies of FIG. 5 is shown. Tubular member 628 of the carriage is shown, as is the swivel point 629 to which a “Cornet” swivel mechanism (or other suitable type of swivel mechanism) attaches. As can be seen in FIG. 6, motion bracket 606 includes attachment flange 665 to which the seat and footrest frame are attached, and attachment flange 670 to which the backrest frame is attached. Followers 623 are shown extending from the motion bracket 606, and have a “wheel” or bushing attached that engages the curved track that is formed within the center section 660 that is made from wood or other suitable material according to the invention. Attached to the center span of motion bracket 606 is a motor assembly 675, which includes a motor 677 that drives a shaft attached to the gear (not shown) to move the bracket assembly. The spur gear and its axel slide through a slot 679 to attach to motor assembly 675. The wooden side panel (not shown), which can be upholstered, attaches to the outside of wooden center section 660 to hide the mechanical assemblies.

While there have been shown and described examples of the present invention, it will be readily apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined by the following claims. Accordingly, the invention is limited only by the following claims and equivalents thereto. 

1. A recliner motion mechanism used for positioning a recliner that includes a seat and a seat back having a fixed positional relationship to each other, comprising: a gear rack adapted to receive a gear that travels in engagement with the gear rack; a gear shaft attached to the gear and driven by a drive motor for rotating the gear and causing it to move along the gear rack; a connection between the drive motor and the seat that causes the seat back to move, as the gear travels along the gear rack, at least at the seat back's lower edge, and generally in the direction of the gear rack; and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the seat back at a position for causing a rotational movement of the seat back relative to a rotational axis of the gear, to guide the seat back during movement of the gear along the gear rack.
 2. The recliner motion mechanism according to claim 1, wherein the gear rack and the curved track are adapted to move the seat and seat back into a zero gravity position.
 3. The recliner motion mechanism according to claim 2, wherein said gear is positioned by the motor at a greater distance from a recliner base when the seat back is in a generally reclined position than when the seat back is in a generally upright position.
 4. The recliner motion mechanism according to claim 3, wherein said drive motor is powered by a battery.
 5. A reclining chair, comprising: a base unit that supports a seat, wherein the base unit does not recline, the seat has a center of gravity, and the seat is operatively connected to a back support member and a leg support member, wherein the seat, back support member, and leg support member have a fixed relative position orientation to each other and can be reclined as a reclining unit from a generally upright sitting position to a reclined position; a motive drive including a motor that operates to move the center of gravity of the seat forward when shifting the unit to the reclined position; and a fixed position curved track, adapted to be engaged by a follower, the follower being connected to the back support member to guide the back support member down during forward movement of the center of gravity of the seat.
 6. The reclining chair according to claim 5, wherein the motive drive and the curved track are adapted such that the reclined position is a zero gravity position.
 7. The reclining chair according to claim 6, wherein the motor is positioned at a higher altitude level when the unit is in the reclined position than when the unit is in the generally upright sitting position.
 8. The reclining chair according to claim 7, wherein the base unit includes a swivel mechanism and the reclining unit can pivot at least partially around a vertical axis.
 9. The reclining chair according to claim 8 where in the reclining unit can pivot 360°.
 10. The reclining chair according to claim 8, wherein said motive drive is powered by a battery.
 11. The reclining chair according to claim 5 where the back support member, in the upright position, is inclined slightly in a forward direction.
 12. A reclining chair, comprising: a base unit that supports a seat, and the seat is operatively connected to a back support member and a leg support member, wherein the seat, back support member, and leg support member have a fixed relative position orientation to each other and can be reclined as a reclining unit from a generally upright sitting position to a reclined position; a motive drive element that operates to move the reclining unit from the generally upright sitting position to the reclined position; and a fixed track guide element, the motive drive element and the fixed track guide element adapted to permit a rotation of the reclining unit with a simultaneous forward translation of the reclining unit when the reclining unit is moving from the generally upright sitting position to the reclined position.
 13. The reclining chair according to claim 12, wherein the base unit is adapted to permit the unit to pivot at least 360° around a vertical axis.
 14. The reclining chair of claim 12 wherein the fixed track is a straight track. 